Fernando Tani, ABB Brazil, Jornadas Técnicas ABB en Chile Electrical integration with IEC61850 Benefits for the mining industry

Transcription

1 Fernando Tani, ABB Brazil, Jornadas Técnicas ABB en Chile 2015 Electrical integration with IEC61850 Benefits for the mining industry

2 Global trends & challenges Mining Industry CAPEX OPEX Energy supply to the process Safety for staff Energy efficiency support Reduce capital investment and operational expenditure CAPEX: Less cabling; Faster commissioning OPEX: Faster troubleshooting; Less spare parts, training and upgrade costs; among others Increase availability of the energy supply to the process Reduce downtime Safety for staff Remove maintenance team from harsh environment Achieve high-standard system for energy efficiency support System with process and power automation integrated May 18, 2015 Slide 2

3 Product Presentation What is Electrical Integration? Electrical integration means integrating Process Automation and Power Automation into the same plant control system Process Automation Power Automation May 18, 2015 Slide 3

4 Product Presentation What is Electrical Integration? Electrical integration means integrating Process Automation and Power Automation into the same plant control system Process Automation Power Automation May 18, 2015 Slide 4

5 Why 800xA with IEC 61850? Technical opportunities with IEC Vertical integration MMS communication Substation operations, Alarm & Event lists Disturbance recordings automatically uploaded Remote logic configuration & parameterization Horizontal integration Protection using GOOSE MMS Real time applications: interlocking, trip commands GOOSE Protection & Control IEDs CI868 board as IED Power Management applications: Load Shedding, Power Demand Monitoring Cabling reduction! May 18, 2015 Slide 5

6 How do we implement IEC61850? Electrical and process integration using 800xA Vertical connectivity - MMS 800xA system system network Substation operation and supervision Alarm and Event Lists with time stamps from IEDs perfect SoE (1 ms resolution) AC800 M controller 18 de maio de 2015 Slide 6 MMS IEC Logging operator actions Audit Trail Disturbance recording automatically uploaded to OPC Server Remote configuration and parameterization through Ethernet network and 800xA aspect Redundancy OPC DA redundancy OPC AE redundancy

7 How do we implement IEC61850? Electrical and process integration using 800xA 800xA system Horizontal connectivity GOOSE: AC800 M controller 18 de maio de 2015 Slide 7 GOOSE system network IEC CI868 board on AC800M CEX bus Fast commands to IEDs useful to contingency local operation (using ABB Process Panel) Real time applications: interlocking, trip commands Power Management applications: Load Shedding, Power Factor Control, Power Demand Monitoring

8 How do we implement IEC61850? Electrical and process integration using 800xA AC800 M controller 800xA system system network MMS IEC GOOSE Vertical and Horizontal connectivity integrated - CI868 board on AC800M has MMS interface too, on the same board Application Suitability for MMS and GOOSE Time critical and supervision applications with the same hardware. Eg. Loadshedding Only board on the market with this feature 18 de maio de 2015 Slide 8

9 Product Presentation Minerals and MIDAS Libraries Feeder Circuit Breaker Motor Link to Faceplate Common Operator Workplaces for Process and Power Automation System Networks System Servers Minerals Library Process Automation AC 800 M controller Fieldbuses IEC (Horizontal) Fieldbuses AC 800M Controller IEC (Horizontal) IEC (Vertical) MIDAS Library Power Automation IEDs IEC (Vertical) Protection & Control IEDs May 18, 2015 Slide 9

10 Product Presentation Description MIDAS stands for Mining Integrated Distribution Automation Systems and it is a 800xA library for Electrical Integration with IEC Turning your substation into gold (referring to King Midas, Greek mythology) MIDAS drives the customer operations to the next level due to its fullenvironment at the control room: graphical status, interlocks, measurements and phasor diagrams; Moreover, the library focuses on engineering efficiency allowing engineers to do projects faster than the convetional method. May 18, 2015 Slide 10

11 MIDAS Library 800xA Library for Electrical Integration Turning your substation into gold MIDAS presents the following features: Full-information environment: tabs for graphical status, interlocks and measurements; Up to 25 bay types, meeting several project requirements, for ABB or 3rd party IEDs; Bay-typical philosophy, reducing engineering efforts for software development; Same look-and-feel as Minerals Library (process control system), and graphical adaption to standards ANSI and IEC; National Language Support (NLS) (English, German and Brazilian Portuguese already configured). 18 de maio de 2015 Slide 11

12 MIDAS Library 800xA Library for Electrical Integration Bay faceplates Up to 25 different Bay Types 18 de maio de 2015 Slide 12

13 MIDAS Library 800xA Library for Electrical Integration Bay Faceplate Description Faceplate: Normal View 1. Alarm Control button 2. Point of Control (Local, Central or Out of Service); 3. Alarm List: all Alarms from Bay; 4. Event List: all Events from Bay; Bay Configuration Manual; Operator Note 7. Bay Graphical Element; 8. Apply Button 9. Cancel Button 10. Position and Interlock Status for the Circuit Breaker and Isolators 18 de maio de 2015 Slide 13

14 MIDAS Library 800xA Library for Electrical Integration Bay Faceplate Description Faceplate: Normal View 11. Position and Interlock Status for the Truck and Earth Switches; 12. Reduced Measurements; 13. Extended Info (Substation Alarm List, IED faceplate, etc); Operation Command Buttons; Equipment Selection Buttons; Point of Control Command Buttons; Maintenance Buttons (Reset commands); 18. Default Apply Button; 19. Additional Tabs: Interlock indications, Alarms and Measurements 18 de maio de 2015 Slide 14

15 MIDAS Library 800xA Library for Electrical Integration Bay Faceplate Description Faceplate: Normal View 1. Opens the IED Faceplate Show Trend Display Voltage, Current, Active Power and Reactive Power 3. Substation Alarm List; 4. Substation Event List Summary of all events occurred with the substation equipment Helps the operator to figure out the reasons of a trip 18 de maio de 2015 Slide 15

16 MIDAS Library 800xA Library for Electrical Integration Bay Faceplate Description Faceplate: Normal View Interlock to Close Open: Shows the interlock messages according to the switch selected Circuit Breaker (up to 20) Isolator and Earth Switch (up to 15) Isolator only (up to 10) Earth Switch only (up to 5) Prio 1 Description de maio de 2015 Slide 16

17 MIDAS Library 800xA Library for Electrical Integration Bay Faceplate Description Faceplate: Normal View Measurements up to 20 configurable measurements 17 predefined measurements Currents (Phase A, B, C and Neutral); Voltages (Line AB, BC and CA); Frequency; Active Power, Reactive Power and Apparent Power; Power Factor; Active Energy, Reactive Energy and Apparent Energy; Active Demand and Reactive Demand. 3 additional measurements 18 de maio de 2015 Slide 17

18 MIDAS Library 800xA Library for Electrical Integration Bay Faceplate Description Faceplate: Extended View Graphic measurements: 5 predefined graphic bars Current A Voltage AB Frequency Active Power Reactive Power The 1st additional measurement 18 de maio de 2015 Slide 18

19 MIDAS Library 800xA Library for Electrical Integration Bay Faceplate Description Faceplate: Extended View Phasor Diagram Represents the phasor diagrams for energy quality analysis Currents A, B and C Voltages A, B and C 18 de maio de 2015 Slide 19

20 Faster troubleshooting & OHS Challenges, Functionalities and Benefits OPEX CAPEX Functionalities Groups 1º 2º 3º Remote Problem Solving Optimized Systems Optimized Engineering Faster Troubleshooting Connect Substations Faster Commissioning Safety for Staff Less Maintenance Costs Reduced Wiring & Cabling Energy Efficiency & Asset Optimization Information Readily Available Reduces Different Technologies May 18, 2015 Slide 20

21 Benefit: OHS, Faster Troubleshooting Remote Problem Solving Improve safety for people Remove maintenance team from electrical danger Faster Troubleshooting & Maintenance More information on automation level allows a quicker analysis and problem solving May 18, 2015 Slide 21

22 Remote Problem Solving Alarm list based on sequence of events Description TRIP 3 rd event Trip x Alarms and events chronologically listed Time synchronization protocols per IEC61850 standard (eg. SNTP - 1ms resolution) x 2 nd event CBR Failure 1 st event Overcurrent Benefits Easier understanding of cause/effect after an electrical fault, with information available remotely May 18, 2015 Slide 22

23 Remote Problem Solving Interlocks & Protections on faceplates Description Easy access to information of active interlocks and fault protection signals x Information displayed on the graphical interface of the bay (faceplate), organized in different tabs Benefits Same information about Interlocks and Protection locally and remotely, in a synthesized manner, allowing faster troubleshooting May 18, 2015 Slide 23

24 Remote Problem Solving Access to disturbances record files Description Disturbance record files are automatically uploaded to the automation system, as they are created on IEDs Protection & Control IEDs Online access to disturbance record a rightclick away Concentrated database for all IEDs on site Benefits No need to go to the substation to upload or view files, allowing faster fault analysis May 18, 2015 Slide 24

25 Remote Problem Solving IED logic configuration & parameterization Description Access to IED allows you to check and change logical configuration and parameterization Communication to IEDs using IEC61850 network Protection & Control IEDs Benefits Shortcut to logic and parameterization software a right-click away, allowing fast access, saving time from maintenance team May 18, 2015 Slide 25

26 Remote Problem Solving Online documentation access Description Single line diagrams, logic diagrams, technical manuals, a right-click away Better revision control of the available documentation for maintenance team Benefits Maintenance team only goes to substation when needed, and get to the faulty place with the right amount of information in-hands May 18, 2015 Slide 26

27 Optimized Systems Less training and spare part costs Common system/architecture System 800xA Less training cost Reduce costs in training due to one common system Process Automation LV Switchgear Drives Motor starters Power Automation Protection & Control IEDs Less spare part cost Optimize common spare parts from same architecture May 18, 2015 Slide 27

28 Optimized Systems Unified Process and Power Automation System Common system/architecture System 800xA Process Automation LV Switchgear Drives Motor starters Power Automation Protection & Control IEDs Description Process and Power Automation in the same plant control system sharing same database, engineering tools and operator stations. Better standardization for new employees single system to learn Benefits Reduced costs in training due to common system knowledge Optimize spare parts from same architecture running into reduced operating costs. Collaborative environment reduces downtime May 18, 2015 Slide 28

29 Optimized Systems Energy Efficiency Support and Asset Optimization Optional Benefits with 800xA system Energy Efficiency Support Power consumption measurements for Energy Management. Asset Optimization Reduce maintenance costs through early problem detection of plant s assets. May 18, 2015 Slide 29

30 Optimized Systems Information Integration Description Electrical and Process data combined for a better asset management. Integrated strategy for engineering, operation and maintenance. Benefits Operators are able to have full insight into the correlation between power and process automation systems for optimized production and power consumption May 18, 2015 Slide 30

31 Optimized Systems Reduced number of different technologies Process and Power Automation Operator Workplace Information in the Right Place at the Right Time Information readily available where you need it. Horizontal Integration IEC Vertical Integration Reduced number of different technologies Control, supervision, protection and measurement with just one standard: IEC May 18, 2015 Slide 31

32 Optimized Systems More Intuitive Systems Horizontal Integration IEC Vertical Integration Description Displaying more, and relevant, data in welldesigned interfaces facilitates the plant supervision, operation and maintenance. Benefits Enable operators to take faster and more accurate decisions Faster troubleshooting for maintenance team May 18, 2015 Slide 32

33 Optimized Systems MV Motor Control with IEC (no gateways) Description Process controllers can send GOOSE and MMS commands directly to MV Motors IED. Horizontal Integration IEC Vertical Integration Benefits No need of hardwired or serial buses between Process and Power automation systems Easier engineering, commissioning and maintenance May 18, 2015 Slide 33

34 Optimized Systems Reduce wiring & cabling Integration without IEC (hardwired) Reduce wiring & cabling IEC allows IEDs to use digital infrastructure instead of wired approaches May 18, 2015 Slide 34

35 Optimized Systems Reduce wiring & cabling Integration with IEC (digital) Reduce wiring & cabling IEC allows IEDs to use digital infrastructure instead of wired approaches Horizontal Integration IEC Vertical Integration May 18, 2015 Slide 35

36 Optimized Systems Connect Substations Connect Substations Substations in different locations integrated under the same system Substations may be far away. Remote control and maintenance provides a real time monitoring at the control room allowing a much faster troubleshooting May 18, 2015 Slide 36

37 Optimized Systems Connect Substations Cauê mine Middle mine 4.5km 1 e-house 5km 8 e-houses Connect Substations Iron mining Itabira/MG, Brazil Maintenance team goes to substation with the right information of the problem allowing a much faster troubleshooting Conceição mine 16 e-houses May 18, 2015 Slide 37

38 Optimized Systems Ethernet / Digital protocols (including GOOSE) Description E-house E-house MMS Messages between IED and Server GOOSE Messages between IEDs Ethernet (CAT5 / 6, Optic Fiber) Connect substations from different and distant locations due to use of Ethernet / Digital protocols for communication between IEDs (IEC 61850) Benefits Remote access allows maintenance team to only go to the substation when needed Less cabling reduces capital expenditure May 18, 2015 Slide 38

39 Optimized Systems Less Upgrade Cost Less Upgrade Cost Upgrade to just one system: 800xA Extended Automation System 800xA dramatically improves plantwide productivity through the following powerful, integrated core functions: Operations software Engineering Knowledge management / Batch management, Asset management Control and I/O May 18, 2015 Slide 39

40 Optimized Systems Faster commissioning ABB Relion IEDs Faster commissioning Typical philosophy for IED programming optimizes test procedures and reduces errors Typical 1 Typical 2 May 18, 2015 Slide 40

41 Optimized Systems Standardized Engineering Typical 01.SCD Typical 02 file.scd file.scd file.scd n file.scd file ABB CCT.SCD file Description Engineering methodology for a faster project development IED Typicals pre-programmed templates allowing a faster configuration IEC Addressing List System 800xA Benefits Faster project development and commissioning reducing your project s risks and decreasing maintenance efforts for mid to big-sized projects May 18, 2015 Slide 41

42 Global trends & challenges Mining Industry CAPEX OPEX Energy supply to the process Safety for staff Energy efficiency support With IEC and 800xA you can: Reduce capital investment and operational expenditure CAPEX: Less cabling; Faster commissioning OPEX: Faster troubleshooting; Less spare parts, training and upgrade costs; among others Increase availability of the energy supply to the process Reduce downtime Safety for staff Remove maintenance team from harsh environment Achieve high-standard system for energy efficiency support System with process and power automation integrated May 18, 2015 Slide 42

43 References Mining Project Name Site Location No. pontos Project Phase IED Vendor Integrated Process Automation Vale Vitória Tubarão Harbour Vale S11D Usina Brazil 213 Commissioning ABB No Brazil 80 Commissioning Multimedidores, Relé Térmico Brazil 530 FAT Test ABB Yes Brazil 32 FAT Test UPS Yes No Vale S11D Mine Brazil 528 FAT Test ABB Yes Brazil 40 FAT Test UPS Yes Vale Carajás +40 Brazil 120 In Operation Schneider Yes Brazil 80 In Operation Multimedidores Yes May 18, 2015 Slide 43

44 References Mining Project Name Site Location No Pontos Project Phase Equipment Vendor Integrated Process Automation Vale Serra Leste Brazil 80 In Operation IED ABB and Schneider Yes Brazil 3 In Operation Multimedidores Yes Vale Itabira - Itabiritos Brazil 402 In Operation IED ABB, Siemens and SEL No Vale Itabira - Cauê Brazil 290 Commissioning IED ABB No Vale Salobo Brazil 100 In Operation IED Schneider Yes Brazil 55 In Operation Multimedidores Yes May 18, 2015 Slide 44

45 References Oil & Gas / Pulp & Paper Project Name Site Location No. IEDs Project Phase IED Vendor Integrated Process Automation Petrobras REDUC Petrobras REGAP Petrobras REPAR Petrobras RLAM Petrobras REFAP Petrobras RPBC Brazil 380 Ready for commissioning. ABB No Brazil 300 Ready for commissioning. SEL No Brazil 670 In Operation 170 ABB, 600 SEL No Brazil 339 Ready for commissioning Schneider and SEL No Brazil 120 In Operation Siemens and SEL No Brazil 300 In Operation GE No RIGESA Brazil 43 In Operation ABB/SEL No Eldorado Brazil 98 In Operation ABB No May 18, 2015 Slide 45

46 Reference S11D, Iron Mining VALE, Brazil Customer s need Integrate Process and Power Automation on a common interface for a huge plant. 100 Mega ton per year of Iron ore. ABB solution Fully Integrated Process and Power Automation: System 800xA 100 AC800M for both Process and Power 135 E-houses IEDs Minerals and MIDAS library GOOSE integration through AC800M Complete Portfolio from ABB DCS, IEDs, E-Houses, LV & MV Switchgears, EOW May 18, 2015 Slide 46

47 Reference S11D, Iron Mining VALE, Brazil Customer s benefits Unique information database for automation. Cross data between power and process. Traceability: historical information for data analysis and action planning Reduced number of operational staff needed, due to system integration and intelligence 9000 to 2500 people Savings in installation costs with standardization of solution 110 km reduction of control cables Savings with reduction of interruption of production time Less exposure to electrical hazard. Increased safety for maintenance team 0 accidents goal May 18, 2015 Slide 47

48 Contact: Fernando Tani Electrical Automation Engineering Coordinator Product Manager MIDAS Library Process Automation Industry Solutions Phone: May 18, 2015 Slide 48

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